Tile blending apparatus



United States Patent l98/lnq; 259/5, 6. Inq; 209/75, 83, 85, 98, 99

[72] Inventors Malcolm A. Schwelker [56] References Cited WorcesterandUNITED STATES PATENTS A I N gg gg Pemylvan' 450,482 4/1891 Coxe 209/99fg April 24 1969 2,615,567 10/1952 Campbell -209/85X 7 Division ofser.N0- 559943 June 23, 1966, 3,172,588 3/1965 Bertold et a]. 209/85X nowPat, N 3,495,569 Primary Examiner-Allen N. Knowles [45] Patented Nov.10, 1970 Anomeyl-lowson and l-lowson [7 3] Assignee American Olean TileCompany, Inc.

Lansdale, Pennsylvania a corporation of New York ABSTRACT: Apparatus forblending ceramic mosaic tile ele- [54] if i g ments into a randomassortment including a rotatable mixing 7 5 a table on which the tileelements are blended by blending pad- [52] US. Cl. 209/75, dles, brushesand the rotation of the table Tile elements are 209/83.209/99 ;259/6removed from the table by rotation of a helical sweep-off [51] Int.Cl. 1. B07b 13/04 brush and pass onto an oscillating separator whichadvances [50] Field of Search 2l4/lnq; single tile elements to aconveyor while separating foreign matter and double-tiles therefromPatentd Nov. 10, 1970 3,539,007

Sheet 1 01'5 INVENTORSZ MALCOLM A. SCHWEIKER WAYNE C. WATSON ATTYS.

Pat nt d Nbv.1 O,' 197O 3,539,007

Sheet 2 0:5

INVENTORS MALCOLM A. SCHWEIKER WAYNE c. WATSON ATTYS.

Patnted Nov. 10, 1970 3,539,007

p Sheet. '3 of s INVENTORSI MALCOLM A. SCHWEIKER WAYNE C. WATSON ATTYS.

Patght edfNov. 10, 1970 I Sheet 1 of 5 INVENTORS. A. S CHWEIKER WAYNE C-WATSON MALCOLM ATTYS.

, TILE BLENDING APPARATUS v The present'application is afdivisionalapplication of our copending application Ser. No. 559,943, filed June23, I966, now U.S. Pat. No. 3,495,569.

The present invention relates to apparatus for blending ceramic mosaictile elements into a random assortment and includes a separator forscreening out foreign matter and double-tiles. The invention hasparticular application to unglazed ceramic mosaic tile elements whichare mostly commonly made in the 1 inch square size for flooring andsimilar uses.

7 The tile elements are conventionally formed into randomly arrangedsheetlike tile assemblies which may for example be of the type-securedby an elastomeric bonding material or of the older paper-backed type.

Inorder to achieve a random grouping of the assembled tile elements, thepresent-invention provides a novel apparatus for effecting a blending ofbatches of tile elements prior to the placement of the elements in.theassembly board. Since tile elements of this size arenormally fired whileon edge in a bed I of sand, grains of sand commonly adhere to the tileedges and tile elements occasionally become stuck together face to face.

The present invention includes novel means for separating double-tilesand for screening out foreign matter such as sand particles, tile chipsand the like.

The invention in summary includes a rotatable blending table upon whicha batch of tile elements is placed. A group of blending paddles andhelical brushes in conjunction with the rotation of the table providea-blending of the tile elements. A sweep-off brush is employed followingthe blending action to remove the tiles from the table in a randommanner and deliver them onto an oscillating separator. Suitable screensare providedonfthe scparator'to sift out dust, sand and foreign matterand to divide out the double-tiles. The novel oscillating movement ofthe separator serves to advance the tiles across. the se'paratorscreenand also to jar loose dust, dirt and other foreign matter which might becarried by or between the tile elements.

It is accordingly a first object of the present invention to provide atile blending apparatus adapted to blend a batch of ceramic tileelements intoa random assortment.

A further object of the invention is toprovide a blending apparatusasdescribed which includes aseparator for removing foreign matter fromthe tile elements and for dividing out double-tiles.

Additional objects and advantages of the invention will be more readilyapparentfrom the following detailed description of an embodiment thereofwhen taken together withthe accompanying drawings in which: v

FIGS. 1a and 1b are a divided side elevational view of a tile blendingand separating apparatus in accordance with the present invention; V

FIG. 2 is a plan'view takenalong line2-2 of FIG. la;

FIG. 3 is a schematic view similar to FIG.'2' showing the operation ofthe tile blending unit;

FIG. 4 is-anelevational view partly in section taken along line 4-4ofFlGi2;

FIG. 5 is a view'partly in sectiontaken alongline 5-5 of FIG. 2;

FIG. 6 is a view partly in sectiontak'en along line 66 of 60 FIG; 5;

FIG. 7 is aview partly in'sectiontaken along line 7-7 of FIG. 2 showingdetails of the tile sweep-off brush assembly;

FIG. 8 is a view partly in section'taken along line 8-8 of FIG. 2showing the separator unit;

FIG 9 is a partial plan viewtakenalong line 9-9 of FIG. 8;

FIG. 10 is a view taken along line 10-l0of FIG. 8;

FIG. '10ais a sectional view taken along line l0a-l0a of FIG. 10;

FIG. 11 is a view taken along line 11-11 ofFIG. 8;-

FIG. 12 is a view taken along line 12-12 of FIG. 8';

FIG. l3yis a partial sectional view taken along line l3-l3 of FIG. 8;and

FIG. 14'is a sectional viewctaken along line 14-14 of FIG. 8 showing theseparation of the double-tiles from the single tiles.

' reference to FIGS. 1-7, the tile blending means associated Theapparatus of the present invention is adapted 'to receive a batch ofceramic tile elements of various colors or shades and to blend the tileelements into a random assortment. The

tiles are screened by the apparatus to remove dust and foreign matterand any "double-tiles are removed by passage of the tiles throughnarrowly spaced rods. The present apparatus is particularly adapted for'use with automatic tile processing equipment and is accordingly shownin conjunction with the tile treating apparatus disclosed in ourcopending application Ser. No. 559,943 referred to above, although itshould be understood that this showing is only an illustration of andnot a limitation on the possible applications of the invention. The tiletreating apparatus serves to present the edges of each tile element to agrinding wheel to remove the residual grains therefrom, following whichthe edges are presented to a primer applicator roll to' apply a primercoating to the tile edges. The tiles are subsequently passed through adrying region to dry the primer and are then distributed in a randomassortment onto a conveyor leading to a tile tray filling station.

-To provide an initial understanding of the embodiment of the inventionillustrated, a brief description of the primary features thereof will bepresented. Referring to the drawings, and

' particularly FIGS. la, 1b, 2 and 3 thereof, the ceramic tile elemeritsT are introduced into the tile treating apparatus on the belt type tileinfeed conveyor 42, the tiles dropping therefrom onto a circular tileblendingtable 44 upon which they are blended into a random assortment bya group of blending paddles, brushes, and the rotationof the table. Thetiles are then transferred from the table by the tile sweep-off brush 45onto the oscillating separator unit 46 whereon dirt and foreign matteras well as double-tiles are separated from the single tiles which areadvanced by the oscillating motion of the separator onto the tile guideconveyor 47. Each tile element is removed from the conveyor 47 by achain-advanced tile clamp assembly and the edges of each tile aresuccessively presented to sanding or grinding wheel assembly 51 toremove the sand grains therefrom. The tiles are further advanced by thetile clamp assemblies through a primer application station 52 and underdryers 53 located therebeneath. The treated tiles are then released intothe tile distributor assemblies 54 which distribute the tile in a randomassortment onto the outfeed conveyor 55 for'delivery to a tile assemblystation (not shown).

With the above general description of the apparatus in mind, theembodiment will now be considered in detail. With with the horizontaltile blending table 44 includes means for rotating the blending-table.As shown in FIG. 4, the table is supported by a plurality of spacedrollers 56 mounted on a suitable supporting frame 57. A central verticalshaft 58 secured at its upper end to the table 44 is journaled by ahearing unit 59 mounted on the frame 57 and at its lower end by abearing unit 60 mounted on the lower frame 61. The shaft 58 and table 44are driven-slowly in rotation through a large sprocket 62 on the shaft58 by chain drives connecting the motor 63, speed reducer 64 and thesprocket 62.

The tile elements advanced by the conveyor 42, upon reaching-the edge 65of the conveyor, drop onto the table 44 which is rotated in acounterclockwise direction as indicated in FIG. 3. The tiles areretained on the table surface by the peripheral tile guide 66 attachedto the frame 57. During rotation of the table, tiles are subjected tothe stirring action of the three blending paddles 67, 68 and 69, each ofwhich as indicated inFIGS. 2 and3, is rotated in a counterclockwisedirection. The blending paddles are preferably made of rubber or otherresilient material and are continuously rotated in a plane parallel tothe table surface by the motor 70 acting through gear reducer 71 anddriving the transverse shaft 72 by means of the drive chain and sprocketassembly 73. Suitable transmission units 74 and 75 connected with theshaft 72 drive the respective vertical shafts 76 and 77 to the lower endof whichthe paddles 69 and 67 are attached. A transmission 78 spacedfrom the shaft 72 and driven thereby through the drive chain andsprocket assembly 80 rotates the vertical shaft 81 carrying the blendingpaddle 68. All three of the blending paddlcs are thus drivencontinuously by the motor 70 in a counterclockwise direction.

A tile spreading brush 82 comprising helically arranged brush elements83 on a horizontal shaft 84 is journaled in pillow blocks 85 dependingfrom the frame member 86 to position the brush parallel to the tablewith the brush elements contacting the table surface as shown in FIG. 5.The spreading brush is disposed diagonally across the table to feed thetile into the paddles and the tile sweep-off brush 45 as illustrated inFIG. 3. A motor 87 and speed reducer 88 mounted on the frame member 86effect rotation of the brush by means of the chain and sprocket assembly90.

The sweep-off brush 45, which is similar to the spreading brush 82although larger in size, includes the helically disposed brush elements91 secured to the shaft 92 which is journaled by pillow blocks 93 on thebrush carriage 94. The sweep-off brush is driven in rotation by a motor95 mounted on the carriage 94 acting through speed reducer 96 and chaindrive 97. The carriage 94 includes the rollers 98 which engage theV-type guide rails 100 on the frame 101 as shown in FIG. 7 to permithorizontal travel of the carriage. As illustrated, the sweep-off brushis radially aligned in parallel contiguous relation with the circularblending table 44 and is of a slightly greater length than the tableradius.

As shown in FIG. 2, the guide rails 100 and the supporting frame 101extend radially outwardly from the blending table across the separatorunit 46. Drive means are provided to effect a continuous reciprocationof the sweep-off brush back and forth along the guide rails, thereciprocating and rotating movement of the brush serving to blend thetiles into a random assortment in the inward stroke and to advance thetiles onto the separator unit during the outward stroke in the mannerschematically illustrated in FIG. 3. The drive means for effecting thebrush reciprocation includes a drive chain 102 disposed between andparallel to the guide rails 100 and connected to the brush carriage 94.The chain 102 at one end passes around idler sprocket 103 on shaft 104extending between the support plates 105 on the frame 101 and at itsopposite end passes over the drive sprocket 106 keyed to drive shaft107. The drive shaft 107 extends beyond the edge ofthe blending table 44and is connected at its outer end by a chain and sprocket assembly 108to the clutch unit 110 located below the table as shown in FIG. 1a. Theclutch unit 110, which is driven by the motor 111 shown in FIG. 2,includes direction reversing means actuated by appropriate limitswitches (not shown) in a known manner to reverse the direction of driveof the drive chain 102 when the sweep-off brush carriage 94 reaches itsend points of travel. The chain 102 is pinned at 112 to the bracket 113of the brush carriage to provide a reciprocating drive of the carriagealong the guide rails 100.

A batch of tiles in introduced onto the blending table 44 from theconveyor 42 when the sweep-off brush 45 is located at its outermostposition 114 shown in broken lines in FIG. 2. As the blending tablerotates in a counterclockwise direction, the tiles are intermixed by theblending paddles 67, 68 and 69 and by the action of the spreading brush82 while the sweepoff brush 45 is slowly advanced from the outermostposition 114 toward the center of the table. The inwardly advancingsweep-off brush is at the same time rotating in a clockwise direction assectionally viewed in FIG. 7 to provide a further shuffling of thetiles. The brush is preferably advanced at a relatively slow rate on theorder of one-half inch per revolution of the blending table. When thesweep-off brush reaches its innermost position shown in FIG. 2, a limitswitch is triggered which reverses the clutch unit 110 thus starting thebrush in the reverse direction to provide a feeding of the tiles ontothe separator unit as shown in FIG. 3. The movement of the brush in thisreversed direction can be somewhat faster than its inward travel rate.

The separator unit 46 includes a rigid base frame 115 above which thetile separator assembly 116 is supported by the flexible support units117 for oscillatory movement. The support units comprise plastic straps118 bolted to the angles 120 and 121 welded respectively to the frame122 of the separator assembly and the base frame 115. The angles 120 and121 are so oriented as to provide an angular disposition of the plasticstraps 118 for a purpose which will shortly become evident. Theseparator assembly 116 is oscillated by an oscillating drive meanscomprising a motor 123 driving a shaft 124 through the drive belt 125and sheave 126 keyed to the shaft, the shaft being journaled by pillowblocks 127 adjustably mounted on a support 128 on the base frame 115.Eccentric cams 130 keyed to the shaft 124 coact with the eccentricstraps 131 which are pivotally connected by means of crank arms 132 tothe downwardly depending angles 133 of the separator frame 122. Thisdrive arrangement provides an oscillation of the entire separatorassembly 116 supported on the plastic straps 118, the plastic havingsufficient flexibility and resilience to permit the desired oscillationsof the assembly while providing sufficient support thereto. Because ofthe angular disposition of the plastic support straps 118, theoscillation of the assembly by the drive means is primarily along aplane normal to the plane of the straps thereby providing a movement ofthe tiles in the desired direction of travel along the separator'unit.

The separator assembly 116 includes a sloping floor 134 attached to theframe 122 which slopes downwardly to an opening 135 located above acollecting bin 136 on the base frame 115. Supported abovethe floor 134by suitable framing elements at the left hand end of the separatorassembly 116 as viewed in FIG. 8 is a perforated rubber covered plate137 shown most clearly in the enlarged view of FIG. 13. The tilesadvanced from the blending table 44 by the sweep-off brush 45 fall fromthe table onto the rubber covered plate 137, the rubber covering of theplate preventing chipping ofthe tiles on contact therewith. Due to theoscillatory movement of the separator assembly 116, the tiles areadvanced on the rubber plate to the right as viewed in FIG. 8 and anydust, tile chips, dirt or other foreign matter passes through theperforations of the plate 137 onto the floor 134 and thence through theopening 135 into the collecting bin 136.

On reaching the edge of the plate 137, the tiles drop onto the upperseparating screen 138 which, as illustrated in FIG. 14, comprises upperand lower rows 140 and 141 of transversely spaced wires, the verticaland horizontal spacing ofwhich is such as to permit the passagethcrebetween ofall single tiles T while any double tiles T are carriedto the end of the upper screen 138 into a double tile discharge trough142 extending transversely thereacross as shown in FIGS. 2 and 8. Thetrough 142 is preferably arranged to direct the double tiles into asuitable container (not shown) for which purpose a sloping bottom isprovided as illustrated.

The wires 140 and 141 of the upper screen 138 are passed through spacedholes in the transverse partition 142 at the left hand end of the screenas viewed in FIG. 8, being secured thereto by nuts on the threaded endthereof, and are fastened to a transverse plate 144 adjacent thedischarge trough 142 at the opposing end thereof in a similar manner. Asindicated in FIGS. 10 and 10a, shims 145 are inserted beneath the wires140 to provide the desired spacing above the wires 141.

The single tiles T, following passage through the upper screen 138, droponto the lower screen 146 made up of wires 147 extending between thepartition 143 and a transverse member 148 in a manner similar to thewires of the upper screen. The wires 147 are of a smaller diameter andspaced closer together to prevent passage of the single tilestherethrough but permitting dirt and dust to drop downwardly onto thefloor 134. As shown in FIG. 11, the single tiles are advanced from thelower screen 146 to the right onto a final separating screen 150 nearlyidentical with the lower screen 146 which provides still anotheropportunity for foreign matter to disassociate itself from the tiles anddrop into the collecting bin 136. The tiles then pass from screen 150onto plate 151 connecting the separator unit with the tile guideconveyor 47.

The operational the device, which has been presented in veyor 42 of abatch of tile elements onto the tile blending table 44. The tilesare fedonto-the blending table when the sweepoff brush 45 is in'the outermostposition 114. As the table is slowly rotated, the paddles 67, 68 and 69are continuously rotated to stir the/tiles and the sweep-off brush isslowly advanced toward the center of the table. The continual rotationof the spreading brush 82 and the sweep-off brush in conjunction withthe rotation of the paddles and the table serves to blend the tiles intoa random assortment. When the sweep-off brush reaches the innermostposition illustrated in FIG. 2, the clutch assembly isactuated toreverse the direction of transverse travel of'the brush and its slowoutward movement advances thetiles onto the oscillating separatorassembly as illus trated inFlG, 3, Dust and foreign matter pass throughthe per forated rubber coated screen 137 and the tiles are advanced ontothe upper screen 138 thro'ughwhich the single tiles drop I onto thelower screen 146, The single tiles are then advanced across the screen150 onto the plate 151 and conveyor 47.

Manifestly, changes in details of construction may be cf fccted by thoseskilled in the art without departing from the spirit and scope of theinvention as defined in and limited solely by the appended claims.

We claim: a

1, Apparatus for blending and separating ceramic tile clementscomprising a horizontal tile biending'table, means for sweep=off brushadapted to receive tiles swept from said table thereby, said separatorassembly comprising a perforated plate upon which said tiles aredeposited fromsaid table, said plate adapted to permit passagetherethrough of foreign matter, a separating screen adapted to separatesingle tiles from double=tiles, and oscillating means for oscillatingsaid plate and screen to advance tile elements across said plate andscreen.

2, Apparatus as claimed in claim 1 wherein said means for mixing tileelements disposed on saidtable comprises at least one blending paddleadjacent said table surface adapted for rotation in a plane parallelwith said table surface, and a tile spreading brush rotatabiy mountedadjacent said table surface and disposed diagonally across said table,and means for rotat= ing said tile spreading brush and said blendingpaddle,

'- 3. Apparatus for blending ceramic tile elements into a randomassortment comprising a horizontal tile blending table,

means for rotating said blending table, at least one blending paddleadjacent said table surface adapted for rotation in a plane parallelwith said table surface, means for rotating said blending paddle, a tilesweep-off brush adjacent said table surface radially aligned with theaxis of rotation of the table, and means for providing rotary as well asreciprocatory movement of said sweep-off brush.

4. Apparatus for blending ceramic tile elements into a random assortmentcomprising ahorizontal tile blending table, means for rotating saidblending table, at least one blending paddle adjacent said table surfaceadapted for rotation in a plane parallel with said table surface, a tilespreading brush rotatably mounted adjacent said table surface anddisposed diagonally across said table, means for rotating said tilespreading brush and said blending paddle, a tile sweep-off brushadjacent said table surface radially aligned with the axis 1 of rotationof the table, and means for providing rotary as well as reciprocatorymovement of said sweep-off brush, the inward movement of said sweep-oftbrush in conjunction with the rotation oi the table, blending paddle,and spreading brush serving to blend the tiles on said table into arandom assortment, the outward movement thereof serving to advance theblended tiles from the table in a random manner.

5. The apparatus as claimed in claim 4 wherein said tile spreading brushand said tile sweep-off brush comprise helical brushes.

' 6. Apparatus as claimed in claim 4 wherein said tile blending table issubstantially circular in shape and wherein said sweep oif brush islonger than the radius of said table.

7. A separator assembly for separating fine matter from ceramic tileelements and for separating single tiles from douhie tiles, saidassembly comprising a perforated plate adapted to continuously receiveceramic tile elements, and to permit passage thcrethrough of foreignmatter, a separating screen adjacent said plate adaptcd'to separatesingle tiles from doubie tiles, spaced flexible support units supportingsaid plate and screen, said support units having flexible supportelements inclined away from the desired direction of advancement of thetile elements, and oscillating means for oscillating said plate andscreen to advance tile elements thereacross,

8 The invention as claimed in claim 7 wherein said oscillating meanscomprises an eccentric cam, means for driving said eccentric cum inrotation, eccentric straps cooperatively mounted on said eccentric cam,and means connecting said straps with said plate and screen.

